U.S. patent number 5,598,679 [Application Number 08/359,915] was granted by the patent office on 1997-02-04 for cast concrete block and method of making same.
Invention is credited to David S. Orton, Michael V. Orton.
United States Patent |
5,598,679 |
Orton , et al. |
February 4, 1997 |
Cast concrete block and method of making same
Abstract
A cast concrete block that is cast on its side and can be
separated into at least three construction blocks to be used in
constructing a retaining wall system. The cast concrete block has a
top face and a bottom face. The block is bounded by an elongate
base side, two elongate edge sides and an elongate top side. First
and second elongate splitting grooves are formed in at least one of
the top face and bottom face. The splitting grooves extend between
the top side and the base side. The splitting grooves are spaced
inwardly from the opposite first and second edge sides. Preferably,
each of the splitting grooves are paired with a corresponding
secondary groove in an opposite face of the block so that each
splitting groove and its corresponding secondary groove are
parallel with each other and lie in a common plane that is
substantially perpendicular to the broad faces of the block.
Inventors: |
Orton; Michael V. (Manti,
UT), Orton; David S. (Princeton, MN) |
Family
ID: |
23415812 |
Appl.
No.: |
08/359,915 |
Filed: |
December 20, 1994 |
Current U.S.
Class: |
52/609; 405/284;
405/286; 52/596; 52/603; 52/604; 52/608 |
Current CPC
Class: |
B28B
17/0027 (20130101); E02D 29/025 (20130101); E04B
2/02 (20130101); E04C 1/395 (20130101); E04B
2002/026 (20130101) |
Current International
Class: |
B28B
17/00 (20060101); E04C 1/00 (20060101); E02D
29/02 (20060101); E04C 1/39 (20060101); E04B
2/02 (20060101); E04C 002/04 () |
Field of
Search: |
;52/98,100,596,608,603,604,609 ;404/34,39,42 ;405/284,285,286 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0040464 |
|
Mar 1981 |
|
EP |
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0091210 |
|
Sep 1983 |
|
EP |
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Other References
Ryan, D. M. "Mechanical Design Considerations for Helical-Scan
Videotape Recorders", SMPTE Journal, V. 87, N. 11 (1978), pp.
767-771. .
Zahn, H. L., "Friction--Its Influence in Rotary Magnetic Tape
Recorders" SMPTE Journal, V. 98, N. 7 (1989), pp. 520-524. .
Database WPI, Derwent Publications, Feb. 1991 Abstract, "Forming
Quality Magnetic Recording Medium . . . ", Yamanaka et al
(91/072,882). .
Wightman, W. O., "Air Bearing Tape Guide", IBM Technical Disclosure
Bulletin, V. 27, N. 6 (Nov. 1984), pp. 3634-3635. .
"Tension Arm Device", Patent Abstracts of Japan, V. 9, N. 163 (Jul.
9, 1985), p. 371. .
Koloseus, J. C., "pneumatic Tape Lifter", IBM Technical Disclosure
Bulletin, V. 27, N. 9 (Feb. 1985), p. 5346. .
Ikuo, S. et al, "Production of Magnetic Recording Medium", Patent
Abstracts of Japan, V. 10, N. 316, p. 510. .
Fujitsu & Okamura, "Tape Tension Control System", Patent
Abstracts of Japan, V. 9, N. 299, p. 408. .
Yamagishi, I., "Contactless Thin Web Conveyor . . . ", Database WPI
Aug. 1979 (Abstract). .
"Appts. mfg. multilayer metal thin film . . . ", Database WPI, May
13, 1988 (Abstract)..
|
Primary Examiner: Friedman; Carl D.
Assistant Examiner: Edwards; W. Glenn
Attorney, Agent or Firm: Crellin; Terry M.
Claims
We claim:
1. A solid cast concrete block that can be separated into at least
three construction blocks to be used in constructing a retaining
wall system, said cast concrete block comprising
a substantially planar top face;
a substantially planar bottom face that is spaced from said top
face and is substantially parallel to said top face;
a substantially straight, elongate base side having a first end and
a second end;
a first substantially straight, elongate edge side having first and
second ends, with the first end of said first edge side being
coexistent with the first end of said base side and with the first
edge side extending substantially perpendicular from said base
side;
a second substantially straight, elongate edge side having first
and second ends, with the first end of said second edge side being
coexistent with the second end of said base side and with the
second edge side extending substantially perpendicular from said
base side so that said second edge side is substantially parallel
with said first edge side;
a first substantially straight, elongate top side having first and
second ends, with the first end of said first top side being
coexistent with the second end of said first edge side and with the
first top side extending toward said second edge side, said first
top side forming an obtuse angle of between about 95 degrees and
115 degrees with said first edge side;
a second substantially straight, elongate top side having first and
second ends, with the first end of said second top side being
coexistent with the second end of said second edge side and with
the second top side extending toward said first edge side, said
second top side forming an obtuse angle of between 95 degrees and
115 degrees with said second edge side;
a third substantially straight, elongate top side having first and
second ends, with the first end of said third top side being
coexistent with the second end of said first top side, and with the
second end of said third top side being coexistent with the second
end of said second top side, so that said third top side is
essentially parallel with said base side;
a first elongate face groove in at least one of said top face and
said bottom face, said first face groove extending between the
second end of said first top side and said base side, with said
first face groove being substantially perpendicular to said base
side; and
a second elongate face groove in at least one of said top face and
said bottom face, said second face groove extending between the
second end of said second top side and said base side, with said
second face groove being substantially perpendicular to said base
side,
whereby said cast concrete block can be split into three individual
construction blocks by breaking the cast concrete block along the
first and second face grooves.
2. A cast concrete block in accordance with claim 1 wherein
there is a first face groove in each of said top face and said
bottom face; and
there is a second face groove in each of said top face and said
bottom face.
3. A cast concrete block in accordance with claim 2 further
comprising
a first elongate side groove extending along the coexistent first
end of said third top side and the second end of said first top
side; and
a second elongate side groove extending along the coexistent second
end of said third top side and the second end of said second top
side.
4. A cast concrete block in accordance with claim 2 further
comprising
a first lip projecting downwardly from said bottom face, with the
first lip being positioned adjacent to the first edge side;
a second lip projecting downwardly from said bottom face, with the
second lip being positioned adjacent to the second edge side;
and
a third lip projecting downwardly from said bottom face, with the
third lip being positioned adjacent to said second face groove in
said bottom face so that said third lip is positioned alongside the
side of said second face groove that faces toward said first edge
side.
5. A cast concrete block in accordance with claim 2 further
comprising
a first lip projecting downwardly from said bottom face, with the
first lip being positioned adjacent to the first edge side;
a second lip projecting downwardly from said bottom face, with the
second lip being positioned adjacent to the second edge side;
and
a third lip projecting downwardly from said bottom surface, with
the third lip being positioned adjacent to said first face groove
in said bottom face so that said third lip is positioned alongside
the side of said first face groove that faces toward said second
edge side.
6. A cast concrete block in accordance with claim 1 further
comprising
at least one third elongate face groove in at least one of said top
face and said bottom face, said third face groove extending between
the base side and said third top side so as to be perpendicular to
said base side and said third top side, with said third face groove
being spaced inwardly of said cast concrete block from said first
and second face grooves,
whereby said cast concrete block can be split into at least four
individual construction blocks by breaking the cast concrete block
along the first, second and third face grooves.
7. A cast concrete block in accordance with claim 6 wherein for
each third face groove in one of the top face and bottom face,
there is a corresponding third face groove in the opposite top face
or bottom face.
8. A cast concrete block in accordance with claim 7 further
comprising
a lip projecting downwardly from said bottom face for each third
face groove in said bottom face, said lip being positioned adjacent
to a corresponding third face groove in said bottom face.
9. A cast concrete block in accordance with claim 7 wherein for
each third face groove in said top face there is a third elongate
side groove in said third top side that extends from the third face
groove in said top face to a corresponding third face groove in
said bottom face.
10. A solid cast concrete block that can be separated into at least
three construction blocks to be used in constructing a retaining
wall system, said cast concrete block comprising
a substantially planar top face;
a substantially planar bottom face that is spaced from said top
face and is substantially parallel to said top face;
a substantially straight, elongate base side having a first end and
a second end;
a first substantially straight, elongate edge side having first and
second ends, with the first end of said first edge side being
coexistent with the first end of said base side and with the first
edge side extending substantially perpendicular from said base
side;
a second substantially straight, elongate edge side having first
and second ends, with the first end of said second edge side being
coexistent with the second end of said base side and with the
second edge side extending substantially perpendicular from said
base side so that said second edge side is substantially parallel
with said first edge side;
a substantially straight, elongate top side having first and second
ends, with the first end of said top side being coexistent with the
second end of said first edge side and with the second end of said
top side being coexistent with the second end of said second edge
side, so that said top side is essentially parallel with said base
side;
a first elongate face groove in each of said top face and said
bottom face, each of said first face grooves extending between said
top side and said base side, with each of said first face grooves
being substantially perpendicular to said base side and said top
side, and further with each of said first face grooves being spaced
inwardly from said first edge side so as to be positioned between
said first edge side and a central transverse axis through said
cast concrete block;
a second elongate face groove in each of said top face and said
bottom face, each of said second face grooves extending between
said top side and said base side, with each of said second face
grooves being substantially perpendicular to said base side and
said top side, and further with each of said second face grooves
being spaced inwardly from said second edge side so as to be
positioned between said second edge side and a central transverse
axis through said block;
a first elongate side groove in said top side that extends from the
first face groove in said top face to the first face groove in said
bottom face;
a second elongate side groove in said top side that extends from
the second face groove in said top face to the second face groove
in said bottom face;
a first lip projecting downwardly from said bottom face, with the
first lip being positioned adjacent to the first edge side;
a second lip projecting downwardly from said bottom face, with the
second lip being positioned adjacent to the second edge side;
and
a third lip projecting downwardly from said bottom face, with the
third lip being positioned adjacent to said second face groove in
said bottom face so that said third lip is positioned alongside the
side of said second face groove that faces toward said first edge
side,
whereby said cast concrete block can be split into three individual
construction blocks by breaking the cast concrete block along the
first and second grooves.
11. A solid cast concrete block that can be separated into at least
three construction blocks to be used in constructing a retaining
wall system, said cast concrete block comprising
a substantially planar top face;
a substantially planar bottom face that is spaced from said top
face and is substantially parallel to said top face;
a substantially straight, elongate base side having a first end and
a second end;
a first substantially straight, elongate edge side having first and
second ends, with the first end of said first edge side being
coexistent with the first end of said base side and with the first
edge side extending substantially perpendicular from said base
side;
a second substantially straight, elongate edge side having first
and second ends, with the first end of said second edge side being
coexistent with the second end of said base side and with the
second edge side extending substantially perpendicular from said
base side so that said second edge side is substantially parallel
with said first edge side;
a substantially straight, elongate top side having first and second
ends, with the first end of said top side being coexistent with the
second end of said first edge side and with the second end of said
top side being coexistent with the second end of said second edge
side, so that said top side is essentially parallel with said base
side;
a first elongate face groove in each of said top face and said
bottom face, each of said first face grooves extending between said
top side and said base side, with each of said first face grooves
being substantially perpendicular to said base side and said top
side, and further with each of said first face grooves being spaced
inwardly from said first edge side so as to be positioned between
said first edge side and a central transverse axis through said
cast concrete block;
a second elongate face groove in each of said top face and said
bottom face, each of said second face grooves extending between
said top side and said base side, with each of said second face
grooves being substantially perpendicular to said base side and
said top side, and further with each of said second face grooves
being spaced inwardly from said second edge side so as to be
positioned between said second edge side and a central transverse
axis through said block;
a first elongate side groove in said top side that extends from the
first face groove in said top face to the first face groove in said
bottom face;
a second elongate side groove in said top side that extends from
the second face groove in said top face to the second face groove
in said bottom face;
a first lip projecting downwardly from said bottom face, with the
first lip being positioned adjacent to the first edge side;
a second lip projecting downwardly from said bottom face, with the
second lip being positioned adjacent to the second edge side;
and
a third lip projecting downwardly from said bottom face, with the
third lip being positioned adjacent to said first face groove in
said bottom face so that said third lip is positioned alongside the
side of said first face groove that faces toward said second edge
side,
whereby said cast concrete block can be split into three individual
construction blocks by breaking the cast concrete block along the
first and second grooves.
12. A cast concrete block in accordance with claim 10 further
comprising
a third elongate face groove in each of said top face and said
bottom face, each of said third face grooves extending between the
base side and said top side so as to be perpendicular to said base
side and said top side, with each of said third face grooves being
spaced inwardly of said cast concrete block from said first and
second face grooves;
a third elongate side groove in said top side that extends from the
third face groove in said top face to the third face groove in said
bottom face;
a fourth lip projecting downwardly from said bottom, said fourth
lip being positioned adjacent to said third face groove in said
bottom face,
whereby said cast concrete block can be split into at least four
individual construction blocks by breaking the cast concrete block
along the first, second and third face grooves.
13. A cast concrete block in accordance with claim 11 further
comprising
a third elongate face groove in each of said top face and said
bottom face, each of said third face grooves extending between the
base side and said top side so as to be perpendicular to said base
side and said top side, with each of said third face grooves being
spaced inwardly of said cast concrete block from said first and
second face grooves;
a third elongate side groove in said top side that extends from the
third face groove in said top face to the third face groove in said
bottom face;
a fourth lip projecting downwardly from said bottom, said fourth
lip being positioned adjacent to said third face groove in said
bottom face,
whereby said cast concrete block can be split into at least four
individual construction blocks by breaking the cast concrete block
along the first, second and third face grooves.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cast concrete blocks that can be
split into three or more individual blocks to be used in the
construction of retaining walls without using mortar. The invention
further relates to a method of casting the concrete blocks on their
side.
2. State of the Art
Cast concrete construction blocks for use in constructing retaining
walls without the use of mortar are well known in the art. The
individual construction blocks are generally of a rectangular shape
and have a lip formed along a rear, bottom side of the blocks. The
construction blocks are laid on top of each other with succeeding
rows being offset by the width of the lip on the blocks. The lip on
each construction block interlocks with the top, rear edge of a
block in a row immediately below the block being laid.
In U.S. Pat. No. 5,017,049 there is disclosed a method of casting
such concrete construction blocks on their side. In a preferred
embodiment of the method taught in U.S. Pat. No. 5,017,049, the
construction blocks are cast as a dual block so that each cast
block can be split into two construction blocks. There is no
disclosure or suggestion in U.S. Pat. No. 5,017,049 of being able
to cast a concrete block so that the cast block can be split into
three or more construction blocks. Being able to cast a parent
block that can be split into three or more construction blocks
would greatly increase the efficiency of the molding machine used
for casting the blocks. Heretofore, however, there has been no
suggestion of a cast concrete block that can be split into three or
more construction blocks. Nor has there been any suggestion of a
method of making a cast concrete block that can be split into three
or more construction blocks.
OBJECTIVES AND BRIEF DESCRIPTION OF THE INVENTION
A principal objective of the invention is to provide a concrete
block that is cast on its side as an integral unit and can
thereafter be split into at least three separate construction
blocks.
An additional objective of the present invention is to provide a
method of casting a concrete block as an integral unit and then
splitting the block into a least three separate construction
blocks.
Another objective of the present invention is to provide a novel
shaped concrete block that is cast as an integral unit and
thereafter split into at least three separate construction blocks,
with at least one of the individual blocks having the shape of a
quadrilateral having two parallel sides, a third side perpendicular
to the parallel sides and a fourth side that is not parallel with
the third side.
The above objectives are achieved in accordance with the present
invention by providing a novel cast concrete block that can be
separated into at least three construction blocks for use in
constructing a retaining wall system. The cast concrete block of
the present invention comprises a substantially planar top face and
a substantially planar bottom face. The bottom face is spaced from
the top face and is substantially parallel to the top face.
The cast concrete block has a substantially straight, elongate base
side. First and second substantially straight, elongate edge sides
extend upwardly, substantially perpendicular from the base side,
with first ends of the first and second edge sides being coexistent
with the respective ends of the base side. The cast concrete block
has an elongate top side that extends between second ends of the
first and second edge sides.
A first elongate groove is provided in at least one of the planar
top face and the planar bottom face. The first groove extends
between the top side and the base side, with the first groove being
substantially perpendicular to the base side and the top side. The
first groove is spaced inwardly from the first edge side so as to
be positioned between the first edge side and a central transverse
axis through the cast concrete block.
A second elongate groove is provided in at least one of the planar
top face and planar bottom face. The second groove extends between
the top side and the base side, with the second groove being
substantially perpendicular to the base side and the top side. The
second groove is spaced inwardly from the second edge side so as to
be positioned between the second edge side and a central transverse
axis through the cast concrete block.
In a preferred embodiment of the present invention there is at
least one first groove in each of the planar top face and planar
bottom face. These first grooves are formed in pairs on opposite
planar faces of the block so that each pair of first grooves are
parallel with each other and lie in a common plane that is
substantially perpendicular to the planar top face and planar
bottom face. In like manner, there is at least one second groove in
each of the planar top face and planar bottom face. These second
grooves are formed in pairs on opposite planar faces of the block
so that each pair of second grooves are parallel with each other
and lie in a common plane that is substantially perpendicular to
the planar top face and planar bottom face.
The cast concrete block can be split into three individual
construction blocks by breaking the cast concrete block along the
first and second grooves.
Additional objects and features of the invention will become
apparent from the following detailed description, taken together
with the accompanying drawings.
THE DRAWINGS
Preferred embodiments of the present invention representing the
best modes presently contemplated of carrying out the invention are
illustrated in the accompanying drawings in which:
FIG. 1 is a pictorial representation of one preferred embodiment of
a cast concrete block in accordance with the present invention that
can be split into three distinct construction blocks;
FIG. 2 is a top view of the cast concrete block of FIG. 1;
FIG. 3 is a side view of the block of FIGS. 1 and 2 taken along
line 3--3 of FIG. 2;
FIG. 4 is another side view of the block of FIGS. 1 and 2 taken
along line 4--4 of FIG. 2;
FIG. 5 is a top view of a cast concrete block similar to the block
of FIG. 1 but which is elongated so that it can be split into four
distinct construction blocks;
FIG. 6 is a side view of the block of FIG. 5 taken along line 6--6
of FIG. 5;
FIG. 7 is another side view of the block of FIG. 5 taken along line
7--7 of FIG. 5;
FIG. 8 is a pictorial representation of another preferred
embodiment of a cast concrete block in accordance with the present
invention;
FIG. 9 is a pictorial view of a modified embodiment of a cast
concrete block similar to that shown in FIG. 8; and
FIG. 10 is a vertical cross section through a wall made of blocks
of the present invention, showing each subsequent row of blocks
displaced backward from the preceding row, with a lip on each block
of the subsequent row engaging the back top side edge of a block in
the preceding row; and
FIG. 11 is a horizontal cross section through a wall made of blocks
of the present invention showing how the blocks that have one end
face that slopes slightly toward the other end face can be used to
construct a wall having a combination of exposed convex and concave
curves.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
Referring now to FIGS. 1-4, there is shown one preferred embodiment
of a cast concrete block 12 in accordance with the present
invention that can be separated into three construction blocks to
be used in constructing a retaining wall system. As illustrated,
the cast concrete block 12 comprises an elongate, solid block
having a substantially planar top face 14 and a substantially
planar bottom face 16 that is spaced from the top face 14, with the
bottom face 16 and bottom face 14 being substantially parallel to
each other.
The perimeter of the block 12 is characterized by a substantially
straight, elongate base side 18, first and second, substantially
straight, elongate edge sides 20 and 22, and a three part top
formed by two slanting top sides 24 and 26 and a flat top side 28.
The first edge side 20 has first and second ends, with the first
end of the first edge side 20 being coexistent with a first end of
the base side 18. The first edge side 20 is oriented so as to
extend substantially perpendicular from the base side 18.
The second edge side 22 has first and second ends, with the first
end of the second edge side 22 being coexistent with the second end
of the base side 18. The second edge side 22 extends substantially
perpendicular from the base side 18 so that the second edge side 22
is substantially parallel with the first edge side 20.
The slanting top sides 24 and 26 are formed by substantially
straight, elongate top segments, each having first and second ends.
The first end of the first top side 24 is coexistent with the
second end of the first edge side 20. The first top side 24 extends
toward the second edge side 22 while also slanting upwardly in a
direction away from the base side 18, so that the first top side 24
forms an obtuse angle of between about 95 degrees and 115 degrees
with the first edge side 20. The first end of the second top side
26 is coexistent with the second end of the second edge side 22.
The second top side 26 extends toward the first edge side 20 while
also slanting upwardly in a direction away from the base side 18,
so that the second top side 26 forms an obtuse angle of between 95
degrees and 115 degrees with the second edge side 22.
The flat top side 28 of the top comprises a third substantially
straight, elongate segment having first and second ends. The first
end of the flat top side 28 is coexistent with the second end of
the first top side 24, and the second end of the flat top side 28
is coexistent with the second end of the second top side 26, so
that the flat top side 28 is essentially parallel with the base
side 18.
A first elongate face groove 30 is provided in at least one of the
top face 14 and the bottom face 16 of the block 12. Each first face
groove 30 extends between the second end of the first top side 24
and the base side 18. Each first face groove 30 is substantially
perpendicular to the base side 18. In the preferred embodiment
illustrated in FIGS. 1-4, there is a first face groove 30 in each
of the top face 14 and bottom face 16, and these first face grooves
30 form a pair of grooves that are positioned parallel with each
other and lie in a common plane that is substantially perpendicular
to the broad faces 14 and 16 of the block 12.
A second elongate face groove 32 is provided in at least one of the
top face 14 and the bottom face 16 of the block 12. Each second
face groove 32 extends between the second end of the second top
side 26 and the base side 18. Each, second face groove 32 is
substantially perpendicular to the base side 18. In the preferred
embodiment illustrated in FIGS. 1-4, there is a second face groove
32 in each of the top face 14 and bottom face 16, and these second
face grooves 32 form a pair of grooves that are positioned parallel
with each other and lie in a common plane that is substantially
perpendicular to the broad faces 14 and 16 of the block 12.
The cast concrete block 12 as illustrated in FIGS. 1-4 can be split
into three individual construction blocks by breaking the cast
concrete block along the first and second face grooves 30 and 32.
The block 12 is preferably split into the separate construction
blocks while the block 12 is standing upwardly from its base side.
The splitting of the block 12 is done by advancing splitting knives
into contact with the top and base side of the block 12. The knives
are oriented in a plane through the pairs of first and second face
grooves 30 and 32.
Because the knives that contact the top of the block 12 make
contact at the juncture of the flat portion 28 and the slanting
portions 24 and 26 of the top, it has been found advantageous to
provide guide grooves in the top for the knives. As shown in FIGS.
2 and 4, the guide grooves comprise a first elongate side groove 36
extending along the coexistent first end of the third top side 28
and the second end of the first top side 24. A second elongate side
groove 38 extends along the coexistent second end of the third top
side 28 and the second end of the second top side 26.
The cast concrete block 12 as illustrated in FIGS. 1-4 further
comprises a first lip 40 projecting downwardly from the bottom face
16. The first lip 40 is positioned adjacent to the first edge side
20. A second lip 42 projects downwardly from the bottom face 16,
with the second lip 42 being positioned adjacent to the second edge
side 22. A third lip 44 projects downwardly from the bottom face
16, and the third lip 44 can be positioned adjacent to either the
first face groove 30 or the second face groove 32 in the bottom
face 16.
As illustrated in FIGS. 1-4, the third lip 44 is positioned
adjacent to the second face groove 32 in the bottom face 16 so that
the third lip 44 is positioned alongside the side of the second
face groove 32 that faces toward the first edge side 20. However,
it is again reiterated that the third lip could just as well
project downwardly from the bottom surface 16 so that the third lip
would be positioned adjacent to the first face groove 30 to lie
alongside the side of the first face groove 30 that faces toward
the second edge side 22.
It has been common in the art to provide lips on concrete
construction blocks such as the lips 40, 42 and 44 as shown in
FIGS. 1-4. These lips are advantageously used to interlock rows of
blocks in a wall without the use of mortar. As shown in FIG. 10,
each succeeding row 90 of blocks 88 is offset rearwardly so that
the lips, shown in FIG. 10 by the reference numeral 92, of the
blocks 88 of the succeeding rows engages the back side of the
blocks 88 in respective lower rows 90. As earth applied pressure
from the back side of the wall, the lips 92 prevent the earth from
forcing one row 90 of blocks 88 to slip forward over a lower row 90
of blocks 88.
As mentioned above, the lips 92 are commonly used on blocks.
However, there is no teaching in the art of being able to form
three and four construction blocks, each having a lip adjacent one
side, by splitting a large, cast block into the three or four
construction blocks. When one large, cast block is split into three
or four separate construction blocks; one must form the lip (if
lips are provided on each construction block) along at least one of
the break lines of the blocks. There is no suggestion in the prior
art that one can form a lip adjacent to and alongside a face groove
in the bottom face of a large, cast block so that the block can be
split along the face groove without damaging the lip that is formed
alongside the face groove.
Referring now to FIGS. 5-7 of the drawings, there is shown a
modified embodiment of the cast block 12. The modified embodiment
of FIGS. 5-7 is very similar to the embodiment shown in FIGS. 1-4
except that the block 12 of the embodiment shown in FIGS. 5-7 is
designed to be broken into four distinct, separate construction
blocks instead of three.
The embodiment of FIGS. 5-7 has the same top face, bottom face,
first and second edge sides 20 and 22, and a three part top formed
by two slanting top sides 24 and 26 and a flat top side 28. The
difference between the embodiment of FIGS. 1-4 and the embodiment
of FIGS. 5-7 is that the latter embodiment has an elongated portion
defined by the flat top side 28 so that that portion can be broken
into two similar rectangular construction blocks.
In the embodiment of the cast concrete block 12 illustrated in
FIGS. 5-7, a third elongate face groove 50 is provided in at least
one of the top face 14 and the bottom face 16. As illustrated in
FIGS. 5-7, there is a face groove 50 in both the top face 14 and
the bottom face 16. The third face grooves 50 extend between the
base side 18 and the third top side 28 so as to be perpendicular to
the base side 18 and the third top side 28, with the third face
groove 50 being spaced inwardly of the cast concrete block 12 from
the first and second face grooves 30 and 32.
In addition to the first, second and third lips 40, 42 and 44 that
the block 12 shown in FIGS. 5-7 has in common with the block 12
shown in FIGS. 1-4, a fourth lip 52 projects downwardly from the
bottom face 16 for each third face groove 50 in the bottom face 16.
Each fourth lip 52 is positioned adjacent to a corresponding third
face groove 50 in the bottom face 16. Further, for each third face
groove 50, there is advantageously provided third elongate side
groove 54 (FIG. 7) in the top side 28 that extends from the third
face groove 50 in the top side 28 to a corresponding third face
groove 50 in the bottom face 16.
The cast concrete block 12 illustrated in FIGS. 5-7 can be split
into four individual construction blocks by breaking the cast
concrete block 12 along the first, second and third face grooves
30, 32 and 50. By further elongation of the flat top side 28 and
providing additional grooves similar to the third grooves 50, the
block 12 could be broken into five or more individual construction
blocks.
The unique, irregular shape of the construction blocks obtained
from the opposite ends of the cast concrete blocks of FIGS. 1-7,
are very advantageous. It should be noted that the top and bottom
faces of these irregular shaped blocks are parallel with each
other, as are the longitudinal, opposite sides of the blocks.
However, the opposite ends of the block are not parallel with each
other. The block is not a rectangular block, but instead, one of
the ends of the block slants toward the other end.
The irregular shaped blocks, i.e., one end slanted toward the
other, are advantageous and highly desirable. When forming a wall
that has an S-shaped curve, as shown in FIG. 11, the irregular
shaped blocks 96 of the present invention are used so that the
spaces between blocks 96 in the S-shaped curve of the wall can be
maintained uniform. As shown in the attached FIG. 11, rectangular
blocks 94 can be used to form the straight portion and the concave
curved portion of a wall. The concave portion will have wide
separations 95 facing the back side of the wall, but that is not a
detraction inasmuch as that side of the wall is covered with dirt.
The exposed side of the wall can be formed with uniform spacing
between blocks 95. The irregular shaped blocks 96 of this invention
are advantageously used to construct a convex portion of the wall.
As shown in FIG. 11, the irregular shaped blocks 96 allow the wall
to be formed with no large spaces on the visible side of the
wall.
Referring now to FIG. 8, of the drawings, there is shown another
modified embodiment of the cast block 12 of the present invention.
The modified embodiment of FIG. 8 is very similar to the previous
embodiments that have been described, i.e., the embodiments shown
in FIGS. 1-4 and in FIGS. 5-7. The block 12 of the embodiment shown
in FIG. 8 is designed to be broken into three distinct, separate,
substantially identical, rectangular construction blocks.
The embodiment of FIG. 8 has the same top face 14, bottom face 16,
base side 18 and first and second edge sides 20 and 22 as the
embodiment of FIGS. 1-4. The embodiment of FIG. 8 differs from the
embodiment of FIGS. 1-4 in that it has a substantially straight,
flat top side 60. The first end of the top side 60 is coexistent
with the second end of the first edge side 20, and the second end
of the top side 60 is coexistent with the second end of the second
edge side 22. The cast block 12 of FIG. 8 is substantially
rectangular in shape, with the top side 60 being essentially
parallel with the base side 18.
In the embodiment of the cast concrete block 12 illustrated in FIG.
8, first and second elongate face grooves 30 and 32 are provided in
the top face 14 and bottom face 16 of the block 12. The grooves 30
and 32 extend between the top side 60 and the base side 18. The
grooves 30 and 32 are substantially perpendicular to the top side
60 and the base side 18, and the grooves 30 and 32 are equally
spaced from their respective first and second edge sides 20 and 22.
The groove 30 is spaced inwardly from the first edge side 20 so as
to be positioned between the first edge side 20 and a central
transverse axis through the block 12. The groove 32 is spaced
inwardly from the second edge side 22 so as to be positioned
between the second edge side 22 and the central transverse axis
through the block 12. In addition, the grooves 30 and 32 are spaced
from each other by the same distance that they are spaced from
their respective first and second edge sides 20 and 22.
In common with the embodiment shown in FIGS. 1-4, the cast concrete
block 12 shown in FIG. 8 has a first face groove 30 in each of the
top face 14 and the bottom face 16, and there is a second face
groove 32 in each of the top face 14 and the bottom face 16. The
cast concrete block 12 shown in FIG. 8 further comprises a first
elongate side groove 36 in the top side 28 that extends from the
first face groove 30 in the top face 14 to the first face groove 30
in the bottom face 16. A second elongate side groove 38 is provided
in the top side 60 so as to extend from the second face groove 32
in the top face 14 to the second face groove 32 in the bottom face
16.
The cast concrete block 12 as illustrated in FIG. 8 further
comprises a first lip 40 projecting downwardly from the bottom face
16. The first lip 40 is positioned adjacent to the first edge side
20. A second lip 42 projects downwardly from the bottom face 16,
with the second lip 42 being positioned adjacent to the second edge
side 22. A third lip 44 projects downwardly from the bottom face
16, and the third lip 44 can be positioned adjacent to either the
first face groove 30 or the second face groove 32 in the bottom
face 16.
As illustrated in FIG. 8, the third lip 44 is positioned adjacent
to the first face groove 30 in the bottom face 16 so that the third
lip 44 is positioned alongside the side of the first face groove 30
that faces toward the second edge side 22. However, it is again
reiterated that the third lip could just as well project downwardly
from the bottom surface 16 so that the third lip would be
positioned adjacent to the second face groove 32 to lie alongside
the side of the second face groove 32 that faces toward the first
edge side 20.
Referring now to FIG. 9 of the drawings, there is shown a modified
embodiment of the cast block 12 that is very similar to the
embodiment shown in FIG. 8 except that the block 12 of the
embodiment shown in FIG. 9 is designed to be broken into four
distinct, separate construction blocks instead of three. The
embodiment of FIG. 9 has the same top face 14, bottom face 16,
first and second edge sides 20 and 22, and a straight, flat top
side 60. The difference between the embodiment of FIG. 8 and the
embodiment of FIG. 9 is that the longitudinal length of the block
12 of the latter embodiment is increased and an additional face
groove has been provided so that the substantially rectangular
shaped block 12 can be broken into four similar sized, rectangular
construction blocks.
In the embodiment of the cast concrete block 12 illustrated in FIG.
9, a third elongate face groove 66 is provided in at least one of
the top face 14 and the bottom face 16. As illustrated in FIG. 9,
there is a face groove 66 in both the top face 14 and the bottom
face 16. The third face grooves 66 extend between the base side 18
and the flat top side 60 so as to be perpendicular to the base side
18 and the top side 60, with the third face groove 66 being spaced
inwardly of the cast concrete block 12 from the first and second
face grooves 30 and 32.
In addition to the first, second and third lips 40, 42 and 44 that
the block 12 shown in FIG. 9 has in common with the block 12 shown
in FIG. 8, a fourth lip 68 projects downwardly from the bottom face
16 for each third face groove 66 in the bottom face 16. Each fourth
lip 68 is positioned adjacent to a corresponding third face groove
66 in the bottom face 16. Further, for each third face groove 66,
there is advantageously provided third elongate side groove 64 in
the top side 60 that extends from the third face groove 66 in the
top side 60 to a corresponding third face groove 66 in the bottom
face 16.
The cast concrete block 12 illustrated in FIG. 9 can be split into
four individual construction blocks by breaking the cast concrete
block 12 along the first, second and third face grooves 30, 32 and
66. By further elongation of the block 12 and by providing
additional grooves similar to the third grooves 66, the block 12
could be broken into five or more individual construction
blocks.
The cast concrete blocks 12 of the present invention are made by a
method comprising the steps of:
(a) filling uncured concrete into an upright mold to cast a green
block on its side so that the green block stands vertically upward
from its side;
(b) forming at least two elongate, vertically oriented, splitting
grooves in one of the upstanding broad faces of the green block as
the green block is being cast;
(c) forming an elongate lip alongside all but one of the splitting
grooves in the one of the broad faces of the green block;
(d) removing the upright mold from the green block that has been
cast; and
(e) curing the green block into a solid block while the green block
remains standing vertically upward from its side; and
The cast concrete block 12 can then be split into at least three
individual construction blocks by breaking the solid block 12 along
the splitting grooves in the broad faces of the solid block 12.
In practicing the method of the present invention, it is
advantageous to include the step of forming at least two secondary
grooves in the broad face opposite the one broad face in which the
splitting grooves are formed. Each secondary groove corresponds to
a respective splitting groove so that each secondary groove and its
corresponding splitting groove are parallel with each other and lie
in a common plane that is substantially perpendicular to the broad
faces of the green block. The method of the present invention can
further include the step of forming a side groove in the top side
of the green block as it is being cast so that there is a side
groove for each splitting groove and each side groove extends
between a splitting groove and a corresponding secondary
groove.
Although preferred embodiments of the cast concrete block 12 of the
present invention have been illustrated and described, it is to be
understood that the present disclosure is made by way of example
and that various other embodiments are possible without departing
from the subject matter coming within the scope of the following
claims, which subject matter is regarded as the invention.
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